Method of and apparatus for processing photographic photosensitive film

ABSTRACT

When any of facilities of a film producing and packaging system suffers a failure, a film processing controller shuts off the film producing and packaging system. The operator repairs a failing facility and manually discharges a length of an elongate film which may possibly be defective. After the failing facility is repaired, the film processing controller is restarted to operate the film producing and packaging system, which then automatically discharges a length of the elongate film corresponding to a preset number of sized films. It is possible to easily and quickly discard a portion of the elongate film which has been made defective by the facility failure.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a method of and an apparatus forprocessing a photographic photosensitive film in a film producing andpackaging system for unreeling a film roll of elongate photographicphotosensitive film, cutting the elongate photographic photosensitivefilm to a film of given length, winding the cut film on a spool, andplacing the wound film into a film cartridge.

[0003] 2. Description of the Related Art

[0004] For producing and packaging a photographic photosensitive film,it has been customary to perform various steps including the steps ofproducing a film of given length, winding the film, placing the woundfilm into a film cartridge, and inserting the film cartridge into acase.

[0005] These various steps are carried out by a facility comprising afilm supply unit for unwinding a film roll and cutting the unwound filmto a film of given length, a film coiling unit for coiling the film ofgiven length on a spool thereby to produce a film coil, a cartridgeproducing unit for staking a cap on an end of a tubular cartridge blanksheet thereby to produce a cartridge with one open end, an assemblingunit for inserting the film coil into the cartridge and staking anothercap on the open end of the cartridge thereby to produce an assembledcartridge, and an encasing unit for placing the assembled cartridge intoa case and attaching a case cap on an open end of the case thereby toproduce a packaged product.

[0006] If the above facility stops its operation due to any of variousfailures or there is a leakage of light into a dark room in thefacility, then the photographic photosensitive film tends to be madedefective, e.g., damaged or exposed to light. When a certainphotographic photosensitive film is made defective, it has been thecustomary practice for the operator to discard all photographicphotosensitive films in the same batch as the defective photographicphotosensitive film. However, this practice is highly uneconomical.

[0007] There has been known a process, as disclosed in Japaneselaid-open patent publication No. 6-266059, of detecting whether aphotographic photosensitive film is acceptable or not, shifting adefective film signal indicative of any detected defective photographicphotosensitive film in synchronism with the movement of the photographicphotosensitive film, and, when the defective film signal is shifted inassociation with a switching position for a delivery path capable ofdischarging a photographic photosensitive film out of the system,switching the delivery path to automatically discharge a defectivephotographic photosensitive film out of the system.

[0008] Depending on the facility suffering a failure or the details ofsuch a failure, a photographic photosensitive film may be subjected to adefect in a substantially long range, and it is highly time-consuming toautomatically discharge a long defective film. Furthermore, if aphotographic photosensitive film is twisted or jammed due to a failureof the film delivery system, then the photographic photosensitive filmcannot be delivered smoothly along the delivery path.

[0009] The elongate photographic photosensitive film unreeled from thefilm roll has a plurality of perforations defined at spaced intervals inside edges thereof. When the photographic photosensitive film is to betrimmed after it has been fed to a cutting position by a predeterminedlength, one of the perforations may possibly be located in the cuttingposition. An end of the photographic photosensitive film which is to betrimmed in the cutting position will serve as a tongue of given lengththat projects out of an assembled cartridge. If a perforation in thefilm is positioned at the leading end of the tongue, then it tends tocause trouble when the film is wound in a camera. Consequently, thecartridge whose film tongue has a perforation in its leading end is poorin quality and is not acceptable as a marketable product. Because thepossibility that a perforation in the film will be positioned at theleading end of the tongue is high, the percentage of defective assembledcartridges is large. This is not economical since a number of expensivecartridges have to be discarded.

[0010] Assembled cartridges produced by the assembling unit are testedby pulling projecting film ends, i.e., tongues, to measure theresistance to the pull. Japanese patent publication No. 5-55022, forexample, discloses a device for measuring the resistance to the actionto pull a projecting film end from an assembled cartridge.

[0011] According to the disclosed device, while an assembled cartridgeis being held by an inspection turret which is continuously rotated, theresistance to the action to pull a projecting film end from theassembled cartridge is measured by a measuring unit associated with afilm pulling mechanism. The measuring unit measures the resistance whilethe assembled cartridge is being continuously delivered.

[0012] When assembled cartridges are produced by the assembling unit,they are inspected in various tests in addition to the measurement ofthe resistance to the film end pulling action. For example, assembledcartridges are inspected to check if a cap is staked on an open end ofthe cartridge in which a film coil has been inserted, and also to checkif the cap is properly staked on the open end.

[0013] Such inspecting processes need to carried out independently inrespective stations in the assembling unit. Accordingly, the assemblingunit requires a relatively large working space and is highly complex instructure. Because the inspecting processes are considerablytime-consuming, they are not efficient to perform.

SUMMARY OF THE INVENTION

[0014] It is a general object of the present invention to provide amethod of processing a photographic photosensitive film in a manner tobe able to easily and quickly discard unacceptable portions of thephotographic photosensitive film which are defective due to facilityfailures.

[0015] A major object of the present invention is to provide anapparatus for processing a photographic photosensitive film in a mannerto be able to reliably discard, with a simple arrangement, defectivefilm portions including joints between photographic photosensitivefilms.

[0016] Another major object of the present invention is to provide amethod of and an apparatus for processing a photographic photosensitivefilm while reliably and easily detecting, with a simple arrangement,whether a perforation defined in a side edge of the photographicphotosensitive film is located in a cutting position or not, when filmsof given length are produced from the photographic photosensitive filmthat is unreeled from a film roll.

[0017] Still another major object of the present invention is to providea method of and an apparatus for processing a photographicphotosensitive film while efficiently performing various inspectingprocesses including a process of measuring the resistance to a pull onthe photographic photosensitive film, in a reduced space and with asimple arrangement.

[0018] The above and other objects, features, and advantages of thepresent invention will become more apparent from the followingdescription when taken in conjunction with the accompanying drawings inwhich preferred embodiments of the present invention are shown by way ofillustrative example.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is a schematic perspective view illustrative of the mannerin which a packaged product is manufactured by a film producing andpackaging system which carries out a method of processing a photographicphotosensitive film according to a first embodiment of the presentinvention;

[0020]FIG. 2 is a schematic plan view of the film producing andpackaging system;

[0021]FIG. 3 is a schematic side elevational view of the film producingand packaging system;

[0022]FIG. 4 is a side elevational view of a film supply unit of a filmprocessing apparatus for carrying out the method of processing aphotographic photosensitive film;

[0023]FIG. 5 is a schematic side elevational view of a succession ofunits ranging from the film supply unit to an assembling unit of thefilm producing and packaging system;

[0024]FIG. 6 is a perspective view of a perforation position inspectingdevice for carrying out the method of processing a photographicphotosensitive film;

[0025]FIG. 7 is a vertical cross-sectional view of the perforationposition inspecting device;

[0026]FIG. 8 is a plan view of a film of given length, showing first andsecond inspecting beams emitted from respective first and secondinspecting units of the perforation position inspecting device;

[0027]FIG. 9 is an enlarged fragmentary plan view of perforations in thefilm in relation to the first and second inspecting beams;

[0028]FIG. 10 is a side elevational view of a film coiling unit and anassembling unit of the film producing and packaging system;

[0029]FIG. 11 is a schematic plan view of the assembling unit whichcarries out a resistance-to-pull inspecting process of the method ofprocessing a photographic photosensitive film;

[0030]FIG. 12 is a perspective view of a resistance-to-pull inspectingdevice for carrying out the resistance-to-pull inspecting process;

[0031]FIG. 13 is an enlarged perspective view of a portion of theresistance-to-pull inspecting device;

[0032]FIG. 14 is a vertical cross-sectional view of a cartridge holdingmechanism, a gap detector, and a height detector of theresistance-to-pull inspecting device;

[0033]FIG. 15 is a side elevational view, partly in cross section, of apulling load inspecting mechanism of the resistance-to-pull inspectingdevice;

[0034]FIG. 16 is a perspective view, partly cut way, of the pulling loadinspecting mechanism;

[0035]FIG. 17 is a block diagram of a in-factory network incorporating afilm production controller for controlling the film producing andpackaging system;

[0036]FIG. 18 is a block diagram of the in-factory network;

[0037]FIG. 19 is a diagram illustrative of the method of processing aphotographic photosensitive film;

[0038]FIG. 20A is a view showing the manner in which the cartridgeholding mechanism is disposed above a cartridge;

[0039]FIG. 20B is a view showing the manner in which the cartridgeholding mechanism is lowered to the cartridge;

[0040]FIG. 20C is a view showing the manner in which a film end is drawnfrom the cartridge;

[0041]FIG. 21 is a diagram showing the relationship between the pulledlength of the film end and the pulling load applied; and

[0042]FIG. 22 is a diagram illustrative of a method of processing aphotographic photosensitive film according to a third embodiment of thepresent invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043]FIG. 1 illustrates in schematic perspective the manner in which apackaged product 12 is manufactured by a film producing and packagingsystem 10 which carries out a method of processing a photographicphotosensitive film according to a first embodiment of the presentinvention. The film producing and packaging system 10 are shown in planand side elevation in FIGS. 2 and 3, respectively.

[0044] As shown in FIGS. 1 through 3, the film producing and packagingsystem 10 generally comprises a film roll storage unit 17 for storing afilm roll 14 of elongate photographic photosensitive film F (hereinafterreferred to as elongate film F), a film supply unit 18 for unwinding thefilm roll 14, cutting the unwound elongate film F into a sized film 16of given length, and supplying the sized film 16, a film coiling unit 22for positioning a spool 20 and the sized film 16 relatively to eachother and winding the sized film 16 on the spool 20, a cartridgeproducing unit 30 for rounding a cartridge blank sheet 24 into a tubularform and staking a cap 26 a on one end of the tubular form thereby toproduce a cartridge 28 with one open end, an assembling unit 36 forinserting a film coil 32, which is made up of the sized film 16 wound onthe spool 20, into the cartridge 28 through the open end thereof, andthen staking another cap 26 b on the open end of the cartridge 28thereby to produce an assembled cartridge 34, and an encasing unit 42for placing the assembled cartridge 34 into a case 38 and attaching acase cap 40 to an open end of the case 38 thereby to produce a packagedproduct 12. The film supply unit 18, the film coiling unit 22, and theassembling unit 36 are housed in a dark room 44, and other devices,i.e., the encasing unit 42, etc. are housed in a bright room 45.

[0045] As shown in FIG. 2, the film supply unit 18, the film coilingunit 22, the assembling unit 36, and encasing unit 42 are arrayed inline with each other along a film producing and packaging process asIndicated by the arrow A. Between the dark room 44 and the bright room45, there extend a first straight feed path 46 for delivering cartridges28 from the cartridge producing unit 30 to the assembling unit 36 and asecond straight feed path 48 for delivering assembled cartridges 34 fromthe assembling unit 36 to the encasing unit 42.

[0046] Downstream of the film producing and packaging process, there isdisposed a parts supply apparatus 58 comprising a spool supply unit 50for supplying spools 20 to the film coiling unit 22, a cap supply unit52 for supplying caps 26 b to the assembling unit 36, a case cap supplyunit 54 for supplying case caps 40 to the encasing unit 42, and a casesupply unit 56 for supplying cases 38 to the encasing unit 42. The spoolsupply unit 50, the cap supply unit 52, the case cap supply unit 54, andthe case supply unit 56 are closely positioned in the housing of theparts supply apparatus 58.

[0047] A cap supply unit 59 for supplying caps 26 a and a cartridgeblank sheet supply unit 60 for supplying cartridge blank sheets 24 on apallet 57 are disposed near the cartridge producing unit 30.

[0048] Packaged product accumulating units 61 a, 61 b, 61 c are disposednear the parts supply apparatus 58. The packaged product accumulatingunits 61 a, 61 b, 61 c and the encasing unit 42 are coupled to eachother by a conveyor 62 which is associated with a semifinished productaccumulating unit 64. A control console 66 is disposed near the conveyor62.

[0049] As shown in FIGS. 4 and 5, the film supply unit 18 comprises afeeder 70 for holding and unwinding a film roll 14, a splicer 72 forsplicing a trailing end of the film roll 14 to a leading end of a newfilm roll 14, a perforator (perforating means) 76 forming perforations74 (see FIG. 1) in opposite longitudinal sides of an elongate film Funwound from the film roll 14, a side printer 78 for printing latentimage data on one or both of the sides of the elongate film F, and acutter (cutting mechanism) 80 for cutting off the elongate film F tofilms 16 of given length.

[0050] The splicer 72 comprises a splicing base 82 for attracting andholding the trailing end of an elongate film F and an auxiliary base 84for attracting and holding the leading end of a new elongate film F. Thesplicer 72 also has a rotatable application base 88 of square crosssection for feeding a splicing tape 86, which comprises a double-sidedadhesive tape, a predetermined length in each feed cycle. Theapplication base 88 is positioned above the splicing base 82 andvertically movable in unison with a tape cutter 92 by a cylinder 90.

[0051] The perforator 76 has a fixed die block 93 and a punch block 94disposed upwardly of the die block 93 and vertically movable by anactuator (not shown) positioned below the die block 93. The perforator76 also has a pair of suction chambers 96, 98 disposed respectivelyupstream and downstream of the punch block 94. A path roller 100 and afeed roller 102 are intermittently rotatably positioned upwardly of thesuction chamber 96, and a sprocket roller 104 and a path roller 106 areintermittently rotatably positioned upwardly of the suction chamber 98.

[0052] The side printer 78 comprises a first printing mechanism 112disposed in confronting relationship to a constant-speed-feed pathroller 110 and a second printing mechanism 116 disposed in confrontingrelationship to a constant-length-feed path roller 114. The firstprinting mechanism 112 records a web-shaped print depending on the typeof the film as a latent image on one or both sides of elongate films F,and the second printing mechanism 116 records a DX bar code, framenumbers, frame number bar codes, a commercial name, depending on thesize of the film as latent images on one or both sides of elongate filmsF.

[0053] As shown in FIG. 5, the cutter 80 comprises a movable blade 118and a fixed blade 120 which are disposed in vertically spaced andconfronting relationship to each other, and cut the elongate film F to apredetermined length as a sized film 16 depending on the desired size ofthe sized film 16. Downstream of the cutter 80, there are disposed endfeed nip rollers 122, an openable and closable guide 124, insertionroller pairs 126, 128, and guide plates 130, 132. The openable andclosable guide 124 is retractable out of the film feed path. As shown inFIG. 4, a discharge port (discharge mechanism) 136 is disposed below theopenable and closable guide 124 for discharging a defective film. Thedischarge port 136 is connected through a pipe 138 to a discharge box(not shown), and is movable in directions normal to the sheet of FIG. 4.

[0054] As shown in FIGS. 4 and 5, the film supply unit 18 incorporates adischarge device 140 which serves as a film processor. The dischargedevice 140 comprises the splicer 72, a trailing end position detector(trailing end position detect mechanism) 142 for detecting the trailingend of an elongate film F fully unreeled from a film roll 14 disposedclosely upstream of the splicer 72, the discharge port 136, a splicingdetector (splicing detecting mechanism) 144 disposed upstream of thecutter 80 for detecting a spliced region of elongate films F, and a filmprocessing controller (control mechanism) 146 for discharging a presetnumber of elongate films F from the discharge port 136 based on a signalfrom the splicing detector 144. The trailing end position detector 142and the splicing detector 144 have respective infrared photosensors 148,150.

[0055] The film supply unit 18 has various detecting means for detectingvarious failures in the respective devices thereof. Specifically, asshown in FIG. 4, the perforator 76 has a first detecting means 152 fordetecting failures produced in the perforating process, e.g., a loopfailure and a bottom-dead-center failure, and the side printer 78 has asecond detecting means 154 for detecting failures such as an encoderwire disconnection. A third detecting means 156 for detecting pathfailures such as a tension roller position failure is disposed on thefilm feed path of the film supply unit 18. A photosensor 158 fordetecting when the dark room 44 is in a bright condition is disposed inthe dark room 44.

[0056] The first, second, and third detecting means 152, 154, 156 andthe photosensor 158 are connected to the film processing controller 146,to which there is connected a timer 160 for measuring a shutdown timefor the facilities.

[0057] A film perforation position inspecting device 161 is disposedclosely upstream of the cutter 80. As shown in FIG. 6, the filmperforation position inspecting device 161 comprises first and secondinspecting means 162, 164 arranged along a passage S and directed towardthe passage S, for applying first and second inspecting beams L1, L2 oflight to the passage S. The perforations 74 defined in one side of theelongate film F unreeled from the film supply unit 18 in the directionindicated by the arrow B move along the passage S.

[0058] The first and second inspecting means 162, 164 compriserespective first and second infrared photosensors which compriserespective first and second light-emitting elements 166, 168 forapplying the respective first and second inspecting beams L1, L2, whichare infrared radiations, to the passage S, and respective first andsecond light-detecting elements 170, 172 positioned in confrontingrelation to the first and second light-emitting elements 166, 168,respectively, across the elongate film F.

[0059] As shown in FIG. 7, an upper film guide 174 and an upper slitplate 176 are disposed below the first and second light-emittingelements 166, 168, and a lower film guide 178 and a lower slit plate 180are disposed above the first and second light-detecting elements 170,172. The upper film guide 174 and the lower film guide 178 have firstand second holes 174 a, 178 a, 174 b, 178 b for passing the first andsecond inspecting beams L1, L2, and the upper slit plate 176 and thelower slit plate 180 have first and second holes 176 a, 180 a, 176 b,180 b.

[0060] The elongate film F has a thickness of 140 μm, and variousdimensions as shown in FIG. 8. Specifically, adjacent ones of theperforations 74 are spaced from each other by a distance R1 of 4.75±0.03mm, and each of the perforations 74 has a length R2 of 1.98±0.02 mm. Theend 182 of a trailing end (so-called “tongue”) 16 c of the sized film 16is spaced from a closer end 182 of the first perforation 74 by adistance T of 1.50±0.60 mm. The first and second inspecting beams L1, L2are spaced from each other by a distance R3 of 4.75n−R2+α mm. The end182 of the trailing end 16 c of the sized film 16 is spaced from thesecond inspecting beam L2 by a distance R4 of 4.75n1−T+α/2 mm. “n”represents an integer established depending on the size of the first andsecond inspecting means 162, 164. In this embodiment, n=3 and α=1.2 mm.“n1” is an integer established depending on the size of the cutter 80and the second inspecting means 164.

[0061] As shown in FIG. 6, the first light-emitting element 166 and thefirst light-detecting element 170 are positioned such that when theelongate film F is accurately positioned with respect to the cutter 80,the first inspecting beam L1 -passes through one perforation 74. Thesecond light-emitting element 168 and the second light-detecting element172 are positioned such that when the elongate film F is accuratelypositioned with respect to the cutter 80, the second inspecting beam L2passes through a perforation 74 which is the third one as counted fromthe perforation 74 through which the first inspecting beam L1 passes.

[0062] Each of the first and second inspecting beams L1, L2 has a beamdiameter ranging from 1.0 mm to 1.5 mm. As shown in FIG. 9, each of thefirst and second inspecting beams L1, L2 is applied as a slit-likedetection beam to perforations 74. The slit-like detection beam has awidth of 0.5 mm and a length of 5 mm for increased detection accuracy.

[0063] The first and second light-detecting elements 170, 172 supplyrespective ON/OFF signals to a decision means 184. The decision means184 determines that neither one of the perforations 74 is located on theend 182, where the elongate film F is to be severed, only when the firstinspecting beam L1 passes a perforation 74 and the second inspectingbeam L2 passes another perforation 74. As shown in FIG. 8, noperforation 74 is located on the end 182 insofar as the elongate film Fdeviates from its proper position within a distance α in a directionopposite to the direction indicated by the arrow B.

[0064] As shown in FIGS. 4, 5, and 10, the film coiling unit 22comprises a turntable 192 fixed to a main shaft 190 rotatable in thedirection indicated by the arrow, a plurality of, e.g., six, spoolchucks 194 mounted at equal angular intervals on the turntable 192, aspool positioner 196 for positioning spools 20 held by the spool chucks194, a plurality of nip rollers 198 for pressing sized films 16 withtheir leading ends 16 a inserted in the spools 20, a prewinder 200 forprewinding the sized films 16, and a winder 202 for winding the sizedfilms 16 which have been prewound by the prewinder 200.

[0065] A first transfer unit 208 and a second transfer unit 210 aredisposed downstream of the film coiling unit 22. The first transfer unit208 receives a film coil 32, which comprises a sized film 16 wound on aspool 20, from one of the spool chucks 194, and converts the film coil32 from a horizontal attitude to a vertical attitude while making a 1800turn about its own axis. The first transfer unit 208 comprises arotatable shaft 212 and a holder 214 rotatable by the rotatable shaft212 in the direction indicated by the arrow.

[0066] The second transfer unit 210 comprises a turntable 218 supportedby a vertical rotatable shaft 216 and rotatable about a vertical axis bythe vertical rotatable shaft 216. A plurality of vertically movablegrips 220 are mounted on the turntable 218. The second transfer unit 210inserts a film coil 32 received from the first transfer unit 208 into asingle-open-ended cartridge 28 placed on an index table 222 of theassembling unit 36. The index table 222 is fixedly mounted on a verticalrotatable shaft 226 for indexing movement to angularly spaced positions.Chucks 228 are mounted on the index table 222 for positioning andholding single-open-ended cartridges 28 in respective stations(described below) corresponding to those angularly spaced positions. Adischarge chute 230 (see FIG. 2) for discharging film coils 32 withdefected films wound thereon is disposed near the second transfer unit210.

[0067] As shown in FIG. 11, the index table 202 can successively beindexed to a single-open-ended cartridge supply station ST1, asingle-open-ended cartridge detecting station ST2, a film-wound spoolinserting station ST3, a spool detecting and chuck opening station ST4,a cap supply station ST5, a chuck centering idle station ST6, a capcrimping station ST7, an idle station ST8, a cap height and torquedetecting station ST9, a tongue (the trailing end 16 c of a sized film16) length detecting station ST10, a product unloading station ST11 fordelivering an assembled cartridge 34 from the index table 222 to thesecond straight feed path 48, and a remaining cartridge detectingstation ST12 for detecting whether an assembled cartridge 34 remains onthe index table 222.

[0068] The single-open-ended cartridge supply station ST1 is associatedwith a loading unit 230 for loading a single-open-ended cartridge 28from the first straight feed path 46 onto the index table 222. The capsupply station ST5 is associated with a cap feed unit 234. The capcrimping station ST7 is associated with a pressing unit 236. The productunloading station ST11 is associated with an unloading unit 238 forunloading an assembled cartridge 34 from the index table 222 to thesecond straight feed path 48.

[0069] As shown in FIGS. 12 and 13, the cap height and torque detectingstation ST9 has a pull resistance inspecting device 240. The pullresistance inspecting device 240 comprises a cartridge holding mechanism242 for holding an assembled cartridge 34, a cap detecting mechanism 244for detecting whether there is a cap 26 b of an assembled cartridge 34,a height detecting mechanism 246 for detecting an increased height ofthe assembled cartridge 34 due to a crimping failure or the like of thecap 26 b, and a pulling load detecting mechanism 248 for detecting aload needed when the trailing end 16 c of a sized film 16 projectingfrom an assembled cartridge 34 is pulled out to a predetermined length,and determining that the assembled cartridge 34 is defective if thedetected load is greater than a predetermined load.

[0070] As shown in FIGS. 13 and 14, the cartridge holding mechanism 242has a rod 250 vertically movable by a cam mechanism (not shown) andsupported by a bearing 252. The rod 250 supports on its lower end aholder 254 for pressing and holding a cap 26 b crimped on the upper endof an assembled cartridge 34. The holder 254 is of a substantiallycylindrical shape and has a downwardly open central recess 255 forclearing the end of the spool 20 projecting upwardly from the assembledcartridge 34.

[0071] The cap detecting mechanism 244 comprises a proximity sensor 256embedded in a peripheral region of the holder 254. The proximity sensor256 serves to detect a cap 26 b, which is made of metal, of theassembled cartridge 34.

[0072] To the rod 250, there is secured an end of a height detectingplate 258 whose opposite end is disposed above a reflective photosensor(distance sensor) 262 of the height detecting mechanism 246 which isembedded in a fixed block 260. The reflective photosensor 262 measures adistance T between itself and the height detecting plate 258 to decidewhether the cap 26 b suffers a crimping failure or not.

[0073] As shown in FIGS. 12 and 15, the pulling load detecting mechanism248 comprises a gripper 270 for gripping a film end 16 c projecting froman assembled cartridge 34, an opening and closing unit 272 for openingand closing the gripper 270, a back-and-forth moving unit 274 for movingthe gripper 270 gripping the film end 16 c back and forth in thedirections indicated by the arrow D, and a load cell 276 for detecting apulling load exerted when the film end 16 c is pulled from the assembledcartridge 34 by the gripper 270.

[0074] The pulling load detecting mechanism 248 has a base 278 on whicha support frame 280 is vertically mounted. As shown in FIG. 15, theback-and-forth moving unit 274 includes a swing arm 282 having an endsupported on the support frame 280 by a bearing 284. The swing arm 282is angularly movable by a cam mechanism (not shown). A slide base 286 isheld in engagement with an opposite end of the swing arm 282.

[0075] The slide base 286 is placed on a rail 288 mounted on the supportframe 280 and extending in the directions indicated by the arrow D. Avertical attachment plate 290 is fixedly mounted on the slide base 286,and has a relatively large opening 292 defined therein. A pair of guiderails 294 a, 294 b extending in the directions indicated by the arrow Dis fixed respectively to upper and lower edges of the attachment plate290.

[0076] A movable plate 296 is supported on the guide rails 294 a, 294 bfor back-and-forth movement in the directions indicated by the arrow D.The movable plate 296 has a vertical slot 298 defined therein. As shownin FIGS. 13 and 15, the gripper 270 comprises a pair of gripping fingers302 a, 302 b mounted respectively on support shafts 300 a, 300 b thatare rotatably supported on the movable plate 296. Gears 304 a, 304 bwhich mesh with each other are fixedly supported respectively on thesupport shafts 300 a, 300 b. An end of a swing rod 306 is fixed to anend of the support shaft 300 a which is longer than the support shaft300 b. A ball 208 is fixed to the other end of the swing rod 306. Thegripping fingers 302 a, 302 b have respective horizontal arms betweenwhich a coil spring 310 is connected, as shown in FIG. 12.

[0077] As shown in FIGS. 15 and 16, the opening and closing unit 272comprises a cylinder 312 mounted on the base 278 and having an upwardlyextending rod 314 whose upper end is coupled to a lower end of avertically movable plate 316. A substantially C-shaped retainer 318 isfixed to an upper end of the vertically movable plate 316. The ball 208is inserted in the retainer 318. The vertically movable plate 316 isvertically slidably supported on the support frame 280 by a guide rail320.

[0078] As shown in FIG. 13, the load cell 276 is mounted on the verticalattachment plate 290 by an angle 322 and coupled to the movable plate296. If a resistance detected by the load cell 276 immediately after thegripping fingers 302 a, 302 b pull the training end 16 c of the sizedfilm 16 out of the assembled cartridge 34 is 400 gf (first pulling load)or less, and a resistance detected by the load cell 276 after thegripping fingers 302 a, 302 b pull the training end 16 c of the sizedfilm 16 out of the assembled cartridge 34 by a predetermined length is250 gf (second pulling load) or less, then the assembled cartridge 34 isdetermined as being accepted.

[0079] As shown in FIG. 2, the second straight feed path 48 extends fromthe dark room 44 into the bright room 45. At a terminal end of thesecond straight feed path 48, there is disposed a discharge chute 324for automatically discharging a defective assembled cartridge 34 ainspected in the assembling unit 36 without delivering it to theencasing unit 42.

[0080] As shown in FIG. 5, the encasing unit 42 comprises an index table328 rotatable about its own axis for indexing movement to angularlyspaced positions. The index table 328 can successively be indexed to acase supply station for supplying a case 38, a cartridge insertingstation for inserting an assembled cartridge 34 into the case 38, acartridge detecting station for detecting whether there is an assembledcartridge 34 or not, a case cap inserting station for inserting a casecap 40 into the open end of the case 38, a normal packaged productdischarging station for discharging a normal packaged product 12, and adefective packaged product discharging station for discharging adefective packaged product 12.

[0081]FIG. 17 shows an in-factory network which incorporates the filmprocessing controller 146 for controlling the film producing andpackaging system 10. The in-factory network includes a molding devicecontroller 330, a film producing controller 146, and an outer shippingpackaging device controller 332 as facility control computers which areindividually controllable.

[0082] The forming device controller 330 sends commands to controlprocess controllers 330 a, 330 b, 330 c, . . . to control variousprocesses for operating a forming device for forming cartridge blanksheets 24 under appropriate conditions.

[0083] The film producing controller 146 sends commands to controlprocess controllers 146 a, 146 b, 146 c, . . . to control a process ofinstalling a film roll 14, inserting an assembled cartridge 34 into acase 38, and attaching a case cap 40 to produce a packaged product 12 ora process of producing a semifinished product which is an assembledcartridge 34.

[0084] The outer shipping packaging device controller 332 sends commandsto control process controllers 332 a, 332 b, 332 c to control a processof packing packaged products 12 in a small box, wrapping the small boxwith a cellophane sheet, or a process of packing a given number of smallboxes storing packaged products 12 in a corrugated box.

[0085] The forming device controller 330, the film producing controller146, and the outer shipping packaging device controller 332 haverespective memories 334, 336, 338 which store production data obtainedfrom the process controllers 330 a, . . . , 146 a, . . . , 332 a . . . ,e.g., data indicative of the numbers of products and semifinishedproducts, data indicative of the numbers of acceptable and defectiveproducts, and inspection data from process controllers for inspectionprocesses.

[0086] The forming device controller 330, the film producing controller146, and the outer shipping packaging device controller 332, which arefacility management computers associated with respective facilities, aremanaged altogether by a film producing process management computer 340,which is managed by a film manufacturing process management computer342, thus making up the in-factory network. The film producing processmanagement computer 340 issues production instruction informationindividually to the forming device controller 330, the film producingcontroller 146, and the outer shipping packaging device controller 332,and gives instructions for setting up conditions for processing orinspecting processes in the production facilities, to those controllers.

[0087] The film manufacturing process management computer 342 issupplied with production plan data, and data of loading and unloadingplans or loaded and unloaded data of materials (raw materials andparts). The production plan data is supplied to the film manufacturingprocess management computer 342 through the control console 66, akeyboard, or a recording medium such as a magnetic disk or the like, andstored in a memory 344. The data of loading and unloading plans orloaded and unloaded data of materials may be supplied to the filmmanufacturing process management computer 342 through the controlconsole 66, a keyboard or a recording medium such as a magnetic disk orthe like, and may also be supplied from the facility managementcomputers.

[0088] A memory 346 of the film producing process management computer340 stores as many prescription tables as the number of types ofphotographic film cartridges (photographic films stored in small boxes)to be manufactured. Each of these prescription tables is allotted anabbreviated product name indicative of the type of a product, andcontains prescription data indicative of types of materials necessary tomanufacture the photographic film cartridges of the type, manufacturingconditions, and inspecting conditions.

[0089] When the film manufacturing process management computer 342 issupplied with the production plan data, the film producing processmanagement computer 340 generates a production instruction table. Theproduction plan data comprise an order number, an abbreviated productname indicative of the type of a product to be manufactured, a plannednumber of products, etc. Based on the abbreviated product name containedin the production plan data, the film producing process managementcomputer 340 searches the prescription tables, and reads allprescription data from the prescription table to which the abbreviatedproduct name is assigned. The film producing process management computer340 can now recognize a prescription type, a material type, materialnames, manufacturing conditions for operating the production facilities,and inspecting conditions therefor. If the film producing processmanagement computer 340 confirms an inventory of materials, then thefilm producing process management computer 340 generates a productioninstruction table. The production instruction table contains aprescription type, the number of products, the names of materials to beused, manufacturing conditions, and inspecting conditions which areassigned with respect to the order number and the abbreviated productname. The items of the production instruction table include fixed itemsthat are uniquely determined once a product type is determined andarbitrary items that can be changed. The fixed items include materialnames and numbers that are differently used depending on the producttype, and these are automatically established. The arbitrary itemsinclude lot numbers of materials, and some manufacturing conditions andinspecting conditions, and these are arbitrarily established.

[0090] The production instruction table thus generated is storedaltogether in the memory 346 of the film producing process managementcomputer 340. Data of the names of materials used, their lot numbers,the manufacturing conditions, and the inspecting conditions in theproduction instruction table are classified for the respectiveproduction facilities by the film producing process management computer340, and transmitted, together with the order number, the abbreviatedproduct name, the prescription type, and the number of products, to thefacility management computers which manage the production facilities.For example, control constants necessary to set up desired product typesare transmitted to the film processing controller 146, which sets aperforating motor speed, a constant feed rate, and a full film lengthdetecting setting to values depending on various product types and sizesupon product type changes.

[0091] As described above, the film producing process managementcomputer 340 controls the facility management computers installedrespectively in combination with the production facilities through thein-factory network, i.e., the forming device controller 330, the filmproducing controller 146, and the outer shipping packaging devicecontroller 332, generates and stores production instruction datadepending on production plan data, generates individual productioninstruction tables for the respective production facilities, andtransmits the individual production instruction tables to thecorresponding facility management computers.

[0092] As shown in FIG. 18, the film producing process managementcomputer 340 manages a cutting machine controller 348 which is used as afacility management computer for a production facility. The filmproducing process management computer 340 manages the film processingcontroller 146 through a film processing information terminal 350.

[0093] The cutter controller 348 transmits slitting conditions, e.g.,established data of a feed speed of a master roll and inspectingconditions for a surface inspecting device in a cutting machine 352, tothe cutting machine 352, thus indicating operating conditions for thecutting machine 352. When the cutting machine 352 is operated, themaster roll is severed to the same width as sized films 16, therebyproducing film rolls 14.

[0094] The film manufacturing process management computer 342 storesinformation as to defects generated in the film manufacturing process,e.g., information as to defects on a blank film caused by aphotosensitive layer coating process, into the memory 344. The filmproducing process management computer 340 has a function as a cut filmlength number information converting means for converting theinformation as to defects on the blank film into information as to thenumber of cut film lengths from the leading end of an elongate film Funreeled from each film roll 14. The film processing controller 146 hasa function as a counting means for counting cut film lengths when thefilm roll 14 is unwound, and a function as a control circuit forautomatically discharging the elongate film F by a length correspondingto the converted number of cut film lengths if the number of counted cutfilm lengths agrees with the converted number of cut film lengths.

[0095] Operation of the film producing and packaging system 10 will bedescribed below with respect to the method of processing a photographicphotosensitive film according to the first embodiment of the presentinvention.

[0096] In a preparatory process carried out by the film producing andpackaging system 10, a support base is coated with a photosensitivelayer to produce a blank film. Defects produced on the blank film whenthe photosensitive layer is coated are detected by the surfaceinspecting device, and stored as film defect information into the memory344 of the film manufacturing process management computer 342.

[0097] The film defect information supplied from the memory 344 to thefilm manufacturing process management computer 342 is transmitted to thefilm producing process management computer 340, which converts the filmdefect information into information as to the number of cut film lengthsfrom the leading end of an elongate film F unreeled from each film roll14 that is slitted to a given width of 35 mm, for example, from theblank film (master roll).

[0098] Specifically, transverse positions of defects on the blank filmare stored as slitted positions, e.g., No. 1, No. 2, . . . , andlongitudinal positions of the defects are stored as, for example, 100m-200 m, 1200 m-1300 m. The film defect information is transmitted fromthe film manufacturing process management computer 342 to the filmproducing process management computer 340.

[0099] The film producing process management computer 340 converts thefilm defect information into cut film length numbers and the numbers ofcut film lengths in the longitudinal direction depending on the numbersof exposures, e.g., 12 exposures, 24 exposures, and 36 exposures, etc.For example, when 1000 24-exposure sized films 16 are manufactured froma film roll 14, if 25th through 50th cut film lengths from the leadingend of the film roll 14 are defective, then film defect information isstored as 25th through 50th cut film lengths.

[0100] The film producing process management computer 340 transmits thefilm defect information of each film roll 14 to the film processinginformation terminal 350. The film processing information terminal 350stores the number of exposures to be produced per sized film, the cutfilm length number, and the number of cut film lengths, and sends theseitems of information to the film processing controller 146.

[0101] In the film supply unit 18, as shown in FIG. 4, the feeder 70 inthe film supply unit 18 is operated to rotate the film roll 14 clockwisein the direction indicated by the arrow to deliver the leading end ofthe unreeled new elongate film F through the splicer 72 to theperforator 76. In the perforator 76, the suction chambers 96, 98 areevacuated to attract an upstream portion of the elongate film F betweenthe feed roller 102 and the path roller 100, and also to attract adownstream portion of the elongate film F between the sprocket roller104 and the path roller 106. The elongate film F is given apredetermined tension between the sprocket roller 104 and the feedroller 102. When the punch block 94 is vertically moved, perforations 74are formed in opposite sides of the elongate film F by the punch block94 in coaction with the die block 93.

[0102] Then, the feed roller 102 and the sprocket roller 104 areintermittently rotated by an indexing device (not shown) to feed theelongate film F intermittently. Thereafter, the punch block 94 isvertically moved to form perforations 74 in opposite sides of theelongate film F in coaction with the die block 93. The above perforatingcycle is repeated to form a succession of perforations in opposite sidesof the elongate film F at a constant pitch (see FIG. 1).

[0103] The perforated elongate film F is fed to the side printer 78where latent images of strip-like prints depending on the film type areformed on one or both sides of the elongate film F by the first printingmechanism 112 (see FIGS. 4 and 5). The printed elongate film F forms afree loop between the path roller 110 and the sprocket 114, after whichthe second printing mechanism 116 above the sprocket 114 records a DXbar code, frame numbers, frame number bar codes, and a commercial name,depending on the film size as latent images on one or both sides ofelongate films F.

[0104] The elongate film F which has passed through the side printer 78is cut by the cutter 80 to form a leading end 16 a of a sized film 16,and then fed in the direction indicated by the arrow B in FIG. 6 by apredetermined length corresponding to the number of exposures of thesized film 16, after which the elongate film F is stopped. Then, thefirst and second inspecting means 162, 164 of the film perforationposition inspecting device 161 are energized.

[0105] Specifically, the first and second light-emitting elements 166,168 of the first and second inspecting means 162, 164 apply therespective first and second inspecting beams L1, L2 to the passage S.The first inspecting beam L1 passes through a perforation 74 and isdetected by the first light-detecting element 170, and the secondinspecting beam L2 passes through another perforation 74 and is detectedby the second light-detecting element 172.

[0106] The first light-detecting element 170 sends an ON signal to thedecision means 184, and the second light-detecting element 172 alsosends an ON signal to the decision means 184. The decision means 184 nowdetermines that neither of the perforations 74 is located on the end182.

[0107] If the perforations 74 are displaced from a predetermined cuttingposition for the elongate film F, then the decision means 184 receives adifferent signal or signals from the first and second light-detectingelements 170, 172. Operation of the decision means 184 based on suppliedsignals will be described in detail below with reference to FIG. 19 andTable 1 below. TABLE 1 Hole Inspecting Inspecting positions beam L1 beamL2 Judgment P1-P2 OFF OFF NG P2-P3 ON OFF NG P3-P4 ON ON OK P4-P5 OFF ONNG

[0108] When the perforations 74 are displaced from a normal positionwithin the distance α as indicated between a hole position P3 shown inFIG. 19 at (c) and a hole position P4 shown in FIG. 19 at (d), the firstinspecting beam L1 passes through one of the perforations 74 and isdetected by the first light-detecting element 170, and the secondinspecting beam L2 passes through the other perforation 74 and isdetected by the second light-detecting element 172. Therefore, thedecision means 184 is supplied with ON signals from both the first andsecond light-detecting elements 170, 172, and determines that thepositions of the perforations 170, 172 are OK, i.e., neither of theperforations 74 is located on the end 182.

[0109] When the perforations 74 are displaced from the normal positionbeyond the distance α in the direction indicated by the arrow B asindicated between a hole position P1 shown in FIG. 19 at (a), the firstand second inspecting beams L1, L2 are positioned between theperforations 74 and blocked by the elongate film F. Therefore, the firstand second inspecting beams L1, L2 are not applied to the first andsecond light-detecting elements 170, 172, which apply OFF signals to thedecision means 184.

[0110] The above state is maintained until the perforations 74 aredisplaced to a position P2 shown in FIG. 19 at (b). Insofar as theperforations 74 in the inspecting position are located in a rangebetween the hole positions P1, P2, the decision means 184 determinesthat the positions of the perforations 74 are NG, i.e., not acceptable.When the perforations 74 in the inspecting position are located in arange between the hole positions P2, P3, the first inspecting beam L1passes through one of the perforations 74 and is detected by the firstlight-detecting element 170, and the second inspecting beam L2 isblocked by the elongate film F. Therefore, the decision means 184 issupplied with an ON signal from the first light-detecting means 170, andan OFF signal from the second light-detecting means 172. The decisionmeans 184 determines that the positions of the perforations 74 are NG,i.e., not acceptable.

[0111] When the perforations 74 are largely displaced from the holeposition P4 to a hole position P5 shown in FIG. 19 at (e) in thedirection indicated by the arrow G (opposite to the direction indicatedby the arrow B), the first inspecting beam L1 is blocked by the elongatefilm F, and the second inspecting beam L2 passes through one of theperforations 74 and is detected by the second light-detecting element172. Therefore, the decision means 184 is supplied with an OFF signalfrom the first light-detecting means 170, and an ON signal from thesecond light-detecting means 172. The decision means 184 determines thatthe positions of the perforations 74 are NG, i.e., not acceptable.

[0112] The elongate film F is cut to a predetermined length by themovable blade 118 and the fixed blade 120 of the cutter 80, producing asized film 16. When the elongate film F is thus cut off, the trailingend 16 c of the sized film 16 which has been severed and the leading end16 a of a sized film 16 to be produced next time are processed. At thesame time that the leading end 16 a of the sized film 16 to be producednext time is processed, holes for engaging a spool are also formed inthe leading end 16 a.

[0113] A defective sized film 16 which is judged by the decision means184 as having either perforation 74 located on the end 182 isautomatically discharged while the NG signal is being shifted, asdescribed later on.

[0114] The film processing controller 146 is counting film lengths cutfrom the elongate film F by the cutter 80, and comparing the countednumber of cut film lengths with the stored film defect information. Ifthe counted number of cut film lengths agrees with the stored filmdefect information, e.g., if the 25th cut film length is detected asbeing disposed in the cutter 80, then the openable and closable guide124 is displaced away from the film feed path, and the discharge port136 is moved onto the film feed path.

[0115] Then, an air blower (not shown) is actuated to cause thedischarge port 136 to attract the elongate film F containing the defect.When the 50th cut film length, which is the trailing end of the defecton the elongate film F, reaches the cutter 80, the cutter 80 is actuatedto sever the elongate film F, and the length of the elongate film Fwhich contains the defect is automatically discharged through thedischarge port 136.

[0116] The sized film 16 has its leading end 16 a delivered into thefilm coiling unit 22. In the film coiling unit 22, as shown in FIGS. 5and 10, a spool 20 is supplied to the spool chuck 174 on the turntable192. Then, the main shaft 190 is intermittently rotated clockwise in thedirection indicated by the arrow, causing the spool positioner 196 toposition the spool 20. Upon further rotation of the turntable 192 in thedirection indicated by the arrow, the leading end 16 a of the sized film16 is inserted into a groove 20 a of the spool 20. The turntable 192 isfurther rotated, and the prewinder 200 is operated to rotate the spool20. The sized film 16 whose leading end 16 a engages the spool 20 is nowprewound on the spool 20 to a predetermined length.

[0117] The turntable 192 is further rotated, and the winder 202 isoperated to wind the sized film 16 on the spool 20, producing a filmcoil 32. After the film coil 32 is held by the holder 214 of the firsttransfer unit 208, the film coil 32 is angularly moved 90° from ahorizontal attitude to a vertical attitude when the holder 214 turns180°. The film coil 32 in the vertical attitude is gripped by the grips220 of the second transfer unit 210. In the second transfer unit 210,the turntable 218 rotates in unison with the vertical rotatable shaft216, bringing the film coil 32 gripped in the vertical attitude by thegrips 220 to a standby position above the chuck 228 placed on the indextable 222 of the assembling unit 36.

[0118] When the second transfer unit 210 receives a film coil 32 with asized film 16 which has been judged as defective by the decision means184, the second transfer unit 210 automatically discharges the defectivefilm coil 32 through the discharge chute 230 based on an NO signal.

[0119] In the cartridge producing unit 30, a cartridge blank sheet 24 isrounded, and a cap 26 a is fitted over an end of the rounded cartridgeblank sheet 24, thus producing a single-open-ended cartridge 28. Thesingle-open-ended cartridge 28 is delivered along the first straightfeed path 46 to the assembling unit 36. As shown in FIG. 1, thesingle-open-ended cartridge 28 is transferred by the loading unit 232 tothe single-open-ended cartridge supply station ST1 on the index table222. The index table 202 is intermittently rotated in the directionindicated by the arrow C to move the single-open-ended cartridge 28 fromthe single-open-ended cartridge supply station ST1 to the film-woundspool inserting station ST3, in which the film coil 32 is inserted intothe single-open-ended cartridge 28 by the second transfer unit 210.

[0120] The single-open-ended cartridge 28 with the film coil 32 insertedtherein is checked in the single-open-ended cartridge detecting stationST2 to detect where there is a trailing end 16 c of a sized film 16 ornot. Thereafter, the single-open-ended cartridge 28 with the film coil32 inserted therein is fed to the spool detecting and chuck openingstation ST4. The spool detecting and chuck opening station ST4ascertains if the length of the trailing end 16 c is positioned in apredetermined range or not to detect whether the film coil 32 isproperly inserted in the single-open-ended cartridge 28 or not.

[0121] The single-open-ended cartridge 28 is then delivered to the capsupply station ST5. In the cap supply station ST5, a cap 26 b deliveredby the cap feed unit 234 is positioned in an upper open end of thesingle-open-ended cartridge 28. In the cap crimping station ST7, the cap26 b is pressed into the upper open end of the single-open-endedcartridge 28 by the pressing unit 236 and crimped in place, producing anassembled cartridge 34. The assembled cartridge 34 is then fed to thecap height and torque detecting station ST9. In the cap height andtorque detecting station ST9, the cartridge holding mechanism 242, thecap detecting mechanism 244, the height detecting mechanism 246, and thepulling load detecting mechanism 248 are synchronously operated.

[0122] Specifically, as shown in FIG. 20A, when the assembled cartridge34 is positioned in alignment with the cartridge holding mechanism 242,the rod 250 is lowered by the cam mechanism (not shown) until the holder254 engages and holds the assembled cartridge 34 (see FIG. 20B). Theproximity sensor 256 of the cap detecting mechanism 244, which isembedded in the holder 254, detects whether there is a cap 26 b which ismade of metal or not.

[0123] When the rod 250 is lowered, the height detecting plate 258 withone end fixed to the rod 250 is also lowered. The distance T between theheight detecting plate 258 and the fixed block 260 is detected by thereflective photosensor 262 of the height detecting mechanism 246. If theheight of the cap 26 b is greater than a predetermined value due, forexample, to a crimping failure of the cap 26 b, then the distance Tdetected by the photosensor 262 differs from an reference value, so thata crimping failure of the cap 26 b can be detected.

[0124] With the assembled cartridge 34 held by the cartridge holdingmechanism 242, the pulling load detecting mechanism 248 is actuated. Asindicated by the two-dot-and-dash lines in FIG. 15, the grips 302 a, 302b of the gripper 270 are open, and the film end 16 c of the assembledcartridge 34 is positioned in the gripper 270.

[0125] The cylinder 312 of the opening and closing unit 272 is operatedto cause the rod 314 to lower the vertically movable plate 316. The ball308 engaging the retainer 318 is swung in the direction indicated by thearrow E, causing the support shaft 300 a connected to the swing rod 306to turn in the direction indicated by the arrow E. The gear 304 afixedly mounted on the support shaft 300 a causes the gear 304 b meshingwith the gear 304 a to move the grips 302 a, 302 b angularly toward eachother, i.e., in a closing direction, so that the tip ends of the grips302 a, 302 b grip the film end 16 c (see FIGS. 15 and 20B).

[0126] Then, the swing arm 282 of the back-and-forth moving unit 274 isswung by the cam mechanism (not shown), thereby moving the slide base286 coupled to the distal end of the swing arm 282 in the directionindicated by the arrow H on the support frame 280 along the rail 288.The attachment plate 290 is fixedly mounted on the slide base 286, andthe movable plate 296 is supported on the attachment plate 290 by theguide rails 294 a, 294 b. Therefore, when the attachment plate 290 ismoved in the direction indicated by the arrow H, the gripper 270 as itgrips the film end 16 c is displaced in the direction indicated by thearrow H (see FIG. 20C).

[0127] At this time, a torque for pulling the film end 16 c acts on thegripper 270, and the movable plate 296 on which the gripper 270 ismounted is displaced relatively to the attachment plate 290 along theguide rails 294 a, 294 b. The load cell 276 fixed to the attachmentplate 290 by the angle 322 detects a pulling load on the film end 16 c.

[0128] Immediately after the film end 16 c is pulled out, there isdeveloped a considerably large sliding resistance due to varyingdirections of fibers of a ribbon (not shown) mounted in the assembledcartridge 34. It is first inspected whether or not the pulling load onthe film end 16 c immediately after the film end 16 c starts to bepulled out is 400 gf (first pulling load) or less. After the film end 16c is pulled out a certain length, since the sliding resistance imposedon the film end 16 c by the ribbon is reduced, it is inspected whetheror not the pulling load on the film end 16 c is 250 gf (second pullingload) or less. The assembled cartridge 34 which is being inspected isjudged as acceptable only when the pulling load on the film end 16 c is400 gf or less immediately after the film end 16 c starts to be pulledout and the pulling load on the film end 16 c is 250 gf or less afterthe film end 16 c is pulled out by the certain length.

[0129] After the assembled cartridge 34 is inspected by the pullresistance inspecting device 240, the film end 16 c is released from thegripper 270, and the rod 250 is lifted to release the holder 254 fromthe assembled cartridge 34. The assembled cartridge 34 is then deliveredto the tongue length detecting station ST10, which detects whether theprojecting length of the film end 16 c falls within a predeterminedrange after the resistance to the pull on the film end 16 c has beeninspected.

[0130] The assembled cartridge 34 is delivered to the second feed path48 by the unloading unit 238 (see FIG. 11). If the assembled cartridge34 is judged as defective by the various inspecting processes in theassembling unit 36, then it is automatically discharged into thedischarge chute 324 without being delivered to the encasing unit 42. Ifthe assembled cartridge 34 is judged as accepted, then it is deliveredfrom the second feed path 48 to the encasing unit 42.

[0131] In the encasing unit 42, a case 38 is delivered to the indextable 328, and the assembled cartridge 34 is inserted into the case 38.Then, a case cap 40 is inserted into the open end of the case 38 inwhich the assembled cartridge 34 has been inserted, producing a packagedproduct 12. The packaged product 12 is fed onto the conveyor 62, fromwhich it is introduced selectively into the packaged productaccumulating units 61 a, 61 b, 61 c.

[0132] If a failure occurs in the various facilities in the film supplyunit 18, the failure is automatically detected, and a failure signal issupplied to the film processing controller 146. For example, a loopfailure or a bottom-dead-center failure in the perforator 76 is detectedby the first detecting means 152, a failure such as an encoder wiredisconnection in the side printer 78 is detected by the second detectingmeans 154, and a path failure such as a tension roller position failurein the film feed path is detected by the third detecting means 156.Based on detected failure signals from these detecting means, the filmprocessing controller 146 shuts off the film producing and packagingsystem 10.

[0133] Then, the operator checks and restores the facility which hasfailed, and manually discharges the elongate film F from the facilitywhich has failed. Specifically, depending on the facility and itsfailure, the operator removes a length of the elongate film F which isdefective from the facility and discards the removed length. When theoperator restarts the film producing and packaging system 10, the filmprocessing controller 146 controls the film producing and packagingsystem 10 to automatically discharges a length of the elongate film Fwhich corresponds to a predetermined number of sized films from thedischarge port 136.

[0134] When the photosensor 158 detects a bright condition in the darkroom 44, the film producing process is interrupted. The length of theelongate film F prior to the cutter 80 is manually discarded by theoperator, and all the elongate film F (and the sized films 16) existingin the facilities subsequent to the cutter 80 is automaticallydischarged. When the opening of a door by which the dark room 44 and thebright room 45 are connected is detected, the film producing process isinterrupted, and the film is discharged. When a malfunction of a shuttermechanism (not shown) which separates the dark room 44 and the brightroom 45 from each other is detected, the film producing process isinterrupted. The operator then checks and restores the shuttermechanism, and manually discards a necessary length of the elongate filmF. Thereafter, the film producing and packaging system 10 is restarted.At this time, a length of the elongate film F which corresponds to apredetermined number of sized films is automatically discharged.

[0135] As shown in FIG. 4, when the feeder 70 is operated to fullyunreel the elongate film F from the film roll 14, the trailing end ofthe elongate film F is detected by the trailing end position detector142. A new film roll 14 is set in the feeder 70, and the leading end ofa new elongate film F is unreeled from the new film roll 14. In thesplicer 72, the trailing end of the fully unreeled elongate film F isattracted to the splicing base 82, and the leading end of the newelongate film F supplied from the feeder 70 is attracted to theauxiliary base 84.

[0136] After the splicing tape 86 is wound around the application base88, the cylinder 99 is actuated to lower the application base 88 and thetape cutter 92. The splicing tape 86 is now applied to the trailing endof the elongate film F on the splicing base 82 across a certain width.Then, the trailing end of the elongate film F is superimposed on andapplied to the leading end of the new elongate film F attracted to theauxiliary base 84, with the splicing tape 86 interposed therebetween.

[0137] At this time, the film processing controller 146 controls thefilm producing and packaging system 10 to operate in a splicingdischarge mode, and issues a command to discharge the spliced region(the splicing tape 86) of the trailing and leading ends of the elongatefilms F. Based on the command, the openable and closable guide 124 ismoved away from the film feed path, and the elongate film F severed bythe cutter 80 starts being drawn and discharged, from its leading end,into the discharge port 136.

[0138] When the spliced region of the new and old elongate films F isdetected by the splicing detector 144 disposed upstream of the cutter80, the new and old elongate films F are fed by a length correspondingto a predetermined number of sized films from the detected splicingregion. The cutter 80 is actuated to cut off the elongate film F, andthe severed elongate film F is discharged as a defective film includingthe spliced region from the discharge port 136.

[0139] The predetermined length of the new and old elongate films Franging from the spliced region to the severed position varies dependingon the number of exposures, e.g., 12 exposures, 24 exposures, or 36exposures, and is set to twice the number of exposures.

[0140] After the film producing and packaging system 10 has startedoperating in the splicing discharge mode, if the spliced region of thenew and old elongate films F is not detected by the splicing detector144 within a predetermined discharge length that has been establisheddepending on the number of exposures, then such a condition is judged asa malfunction, and the film producing and packaging system 10 isautomatically shut off. The predetermined discharge length is equal to10 sized films for 12 exposures, 7 sized films for 24 exposures, and 5sized films for 36 exposures, for example.

[0141] According to the first embodiment, in the film producing andpackaging system 10, when either one of the facilities suffers afailure, e.g., either one of the first, second, and third detectingmeans 152, 154, 156 detects a failure, the film processing controller146 temporarily shuts off the film producing and packaging system 10.Then, the operator repairs the facility which has failed, and manuallydischarges a length of the elongate film F which is judged as madedefective by the failure. When the operator restarts the film producingand packaging system 10, a length of the elongate film F equal to apresent number of sized films is automatically discharged with respectto the facility which has failed.

[0142] Therefore, the operator can quickly discard a desired film of theelongate film F which is likely to have been made defective by afacility failure. The process of discarding the defective length of theelongate film F is much quicker and easier than if the defectiveelongate film F were automatically discharged in its entirety.

[0143] After the defective length of the elongate film F is manuallydiscarded by the operator, a length of the elongate film F which isequal to a preset number of sized films is automatically discharged.Consequently, any elongate film F which may possibly be defective willnot remain in the film producing and packaging system 10. As a results,high-quality films are produced and packaged using acceptable,defect-free elongate films F.

[0144] The timer 160 is connected to the film processing controller 146for measuring a time in which the film producing and packaging system 10is shut off. If the measured time exceeds a predetermined time, thenwhen the film producing and packaging system 10 is restarted, a lengthof the elongate film F which is equal to a preset number of sized filmsis automatically discharged. In this manner, a length of the elongatefilm F which may possibly have been flexed or bent is reliably discardedfrom the film producing and packaging system 10.

[0145] According to the first embodiment, furthermore, a defect producedon a blank film when the blank film is manufactured is stored by thefilm manufacturing process management computer 342, and the defectinformation is converted into information as to the number of cut filmlengths as counted from the leading end of the elongate film F unreeledfrom the film roll 14. As the film roll 14 is unwound, film lengths cutfrom the elongate film F are counted. When the counted number of cutfilm lengths agrees with the converted number of cut film lengths, theposition of the defect is identified. Therefore, the defect on theelongate film F can automatically and reliably be discharged through thedischarge port 136.

[0146] According to the first embodiment, furthermore, the trailing endof the elongate film F which has fully been unreeled from the film roll14 is detected by the trailing end position detector 142, and spliced tothe leading end of an elongate film F to be newly unreeled by thesplicer 72. Then, when the elongate film F upstream of the cutter 80 isdischarged through the discharge port 136, the spliced region of the newand old elongate films F is detected by the splicing detector 144. Basedon a detected signal from the splicing detector 144, the elongate film Fis fed by a length corresponding to a preset number of sized films, andthen severed by the cutter 80 and discharged through the discharge port136. Consequently, the elongate film F including the spliced region caneasily and reliably be discarded under simple control with a simplearrangement.

[0147] According to the first embodiment, as shown in FIG. 6, with theelongate film F fed a given length toward the cutter 80 and stopped atthe cutting position, the first and second inspecting means 162, 164 areenergized to apply the first and second inspecting beams L1, L2 to thepassage S. Only when the first inspecting beam L1 passes through aperforation 74 and is detected by the first light-detecting element 170,and the second inspecting beam L2 passes through another perforation 74and is detected by the second light-detecting element 172, the decisionmeans 184 determines that neither one of the perforations 74 is locatedon the end 182.

[0148] Therefore, for cutting (trimming) the trailing end 16 c of thesized film 16 with the cutter 80, it is possible to detect reliablywhether perforations 74 are located on the end 182 of the trailing end16c. Inasmuch as defective sized films 16 are automatically dischargedwithout being delivered to the assembling unit 36, only assembledcartridges 34 containing defect-free sized films 16 can be produced. Theoutwardly projecting trailing ends 16 c of these assembled cartridges 34are not defective, and hence the percentage of defective assembledcartridges 34 which are produced is greatly reduced.

[0149] According to the first embodiment, the decision means 184determines that the perforations 74 are properly positioned only whenthe first inspecting beam L1 passes through a perforation 74 and isdetected by the first light-detecting element 170, and the secondinspecting beam L2 passes through another perforation 74 and is detectedby the second light-detecting element 172. When the first and inspectingbeams L1, L2 do not pass due to dust or dirt through the elongate filmF, the decision means 184 always judges the elongate film F asunacceptable, but does not judge the elongate film F erroneously asacceptable. Consequently, packaged products 12 with defective sizedfilms 16 contained therein will not be shipped from the film producingand packaging system 10.

[0150] Single-open-ended cartridges 28 manufactured from cartridge blanksheets 24 are highly expensive as unit components. Since the number ofassembled cartridges 34 including single-open-ended cartridges 28 whichare discarded is greatly reduced, the film producing process carried outby the film producing and packaging system 10 is highly economical.

[0151] According to the first embodiment, furthermore, the position ofthe perforations 74 is inspected on the basis of ON/OFF signals producedby the first and second inspecting means 162, 164 each comprising aphotosensor. Accordingly, the film perforation position inspectingdevice 161 is effectively simple and small as a whole, and can bemanufactured relatively inexpensively.

[0152] According to the first embodiment, the pull resistance inspectingdevice 240 has the cartridge holding mechanism 242, the cap detectingmechanism 244, the height detecting mechanism 246, and the pulling loaddetecting mechanism 248. When the assembled cartridge 34 is pressed andheld by the cartridge holding mechanism 242 for pulling the film end 16c from the assembled cartridge 34 by the pulling load detectingmechanism 248, the cap detecting mechanism 244 and the height detectingmechanism 246 are actuated.

[0153] In synchronism with the operation of the cartridge holdingmechanism 242 to press and hold the cartridge 34, the proximity sensor256 detects whether there is a cap 26 b or not, the reflectivephotosensor 262 inspects the cap 26 b for a crimping failure or thelike, and the pulling load detecting mechanism 248 detects a pullingload on the film end 16 c. Consequently, the processes of detectingwhether there is a cap 26 b or not, inspecting the cap 26 b for acrimping failure or the like, and detecting a pull resistance to thefilm end 16 c are carried out substantially simultaneously in a singleoperation. Therefore, these inspecting processes are effectedefficiently.

[0154] The proximity sensor 256 of the cap detecting mechanism 244 isembedded in the cartridge holding mechanism 242, and the heightdetecting mechanism 246 is combined with the cartridge holding mechanism242. Thus, the pull resistance inspecting device 240 is highlysimplified in overall arrangement.

[0155] The pulling load detecting mechanism 248 has the load cell 276for detecting the pulling load on the film end 16 c in two stages.Specifically, the load cell 276 detects whether the pulling load on thefilm end 16 c is acceptable or not when the film end 16 c is subjectedto a sliding resistance (frictional resistance) imposed by the ribbon(not shown) in the cartridge 34 immediately after the film end 16 cstarts being pulled out, and also detects whether the pulling load onthe film end 16 c is acceptable or not when the film end 16 c is pulledout by a given length and the sliding resistance imposed by the ribbonis reduced. As a result, it is possible to produce high-qualityassembled cartridges 34.

[0156] A method of processing a film according to a second embodiment ofthe present invention will be described below with reference to FIGS. 4and 5. The method according to the second embodiment is carried out bythe film producing and packaging system 10.

[0157] When the trailing end of an elongate film F being delivered isdetected by the trailing end position detector 142, the trailing end ofthe elongate film F is spliced to the leading end of a new elongate filmF from a new film roll 14 by the splicer 72. At this time, the filmprocessing controller 146 controls the film producing and packagingsystem 10 to operate in the splicing discharge mode, and issues acommand to discharge the spliced region of the new and old elongatefilms F. Based on the command, the elongate film F is severed by thecutter 80 and then starts being drawn and discharged, from its leadingend, into the discharge port 136.

[0158] Based on the detected signal from the trailing end positiondetector 142, the film processing controller 146 delivers the elongatefilm F by a predetermined discharge length depending on the number ofexposures of sized films 16. The elongate film F is then severed by thecutter 80 and then discharged from the discharge port 136. The dischargelength is equal to 10 sized films for 12 exposures, 7 sized films for 24exposures, and 5 sized films for 36 exposures, for example. In thesecond embodiment, therefore, the elongate film F including the splicedregion can easily and reliably be discarded under simple control with asimple arrangement.

[0159] After the film producing and packaging system 10 has startedoperating in the splicing discharge mode, if the spliced region of thenew and old elongate films F is not detected by the splicing detector144 within the predetermined discharge length that has been establisheddepending on the number of exposures, then such a condition is judged asa malfunction, and the film producing and packaging system 10 isautomatically shut off. Thus, the spliced region can be discarded morereliably.

[0160] A method of processing a film according to a third embodiment ofthe present invention will be described below with reference to FIG. 22and Table 2. The method according to the third embodiment is carried outusing the film perforation position inspecting device 161. TABLE 2 HoleInspecting Inspecting positions beam L1 beam L2 Judgment    -P10 OFF OFFNG P10-P11 OFF ON OK P11-P12 ON ON NG P12-P13 ON OFF NG

[0161] According to the third embodiment, the decision means 184determines that neither of the perforations 74 is located on the end 182only when the first inspecting beam L1 is block by the elongate film F,and the second inspecting beam L2 passes through a perforation 74.

[0162] According to the third embodiment, as shown in FIG. 22, the firstand second inspecting beams L1, L2 are spaced from each other by adistance R3 a of 4.75n2+H mm where n2=3, H=1.2 mm.

[0163] When the perforations 74 are displaced from a normal position bya distance H or greater as indicated by a hole position P10 shown inFIG. 22 at (a), the first and second inspecting beams LI, L2 are blockedby the elongate film F, and are not applied to the first and secondlight-detecting elements 170, 172. Therefore, the decision means 184 issupplied with ON signals from both the first and second light-detectingelements 170, 172, and determines that the positions of the perforations170, 172 are NG.

[0164] When the perforations 74 are located within a range from the holeposition P10 to a hole position P11 shown in FIG. 22 at (b), the secondinspecting beam L2 passes through one of the perforations 74 and isdetected by the second light-detecting element 172, and the firstinspecting beam L1 is blocked by the elongate film F. Therefore, thedecision means 184 is supplied with an ON signal from the secondlight-detecting means 172, and an OFF signal from the firstlight-detecting means 170. The decision means 184 determines that thepositions of the perforations 170, 172 are OK, i.e., neither of theperforations 74 is located on the end 182.

[0165] When the perforations 74 are located within a range from the holeposition P11 to a hole position P12 shown in FIG. 22 at (c), the firstinspecting beam L1 passes through one of the perforations 74 and isdetected by the first light-detecting element 170, and the secondinspecting beam L2 passes through another perforation 74 and is detectedby the second light-detecting element 172. Therefore, the decision means184 is supplied with ON signals from both the first and secondlight-detecting means 170, 172. The decision means 184 determines thatthe positions of the perforations 170, 172 are NG.

[0166] When the perforations 74 are located within a range from the holeposition P12 to a hole position P13 shown in FIG. 22 at (d), the secondinspecting beam L2 is blocked by the elongate film F, and the firstinspecting beam Li passes through one of the perforations 74 and isdetected by the first light-detecting element 170. Therefore, thedecision means 184 is supplied with an ON signal from the firstlight-detecting means 170, and an OFF signal from the secondlight-detecting means 172. The decision means 184 determines that thepositions of the perforations 170, 172 are NG.

[0167] According to the third embodiment, therefore, the decision means184 determines that neither of the perforations 74 is located on the end182 only when the first inspecting beam Li is block by the elongate filmF, and the second inspecting beam L2 passes through a perforation 74.The third embodiment thus offers the same advantages as those of thefirst embodiment.

[0168] According to the present invention, as described above, in theevent that the facilities of the film producing and packaging systemsuffer a failure, the operator repairs a failing facility and manuallydischarges a length of the photographic photosensitive film which maypossibly be defective, after which a length of the photographicphotosensitive film corresponding to a preset number of sized films isautomatically discharged. The operator can thus more quickly and easilydischarge the defective length of the photographic photosensitive filmmanually than if it were automatically discharged. When another lengthof the photographic photosensitive film is subsequently automaticallydischarged, the defective photographic photosensitive film is reliablydiscarded. Accordingly, it is possible to produce and packagehigh-quality photographic photosensitive films.

[0169] Furthermore, after the trailing and leading ends of photographicphotosensitive films are spliced, a length of the spliced photographicphotosensitive film corresponding to a preset number of sized films isdischarged on the basis of a detected signal representing the splicedregion or a detected signal representing the trailing end. Consequently,the photographic photosensitive film including the spliced region caneasily and reliably be discarded under simple control with a simplearrangement.

[0170] Moreover, with the photographic photosensitive film stopped inthe cutting position, the first and second inspecting beams are appliedto a perforated side edge of the photographic photosensitive film. It isjudged whether either one of perforations is located in the cuttingposition by detecting whether the first and second inspecting beams passthrough respective perforations in the photographic photosensitive film.Packaged products containing photographic photosensitive films in whichperforations are located at severed ends thereof will be prevented frombeing shipped. Therefore, high-quality packaged products can efficientlybe manufactured.

[0171] Furthermore, a process of inspecting whether a cap is mounted ona cartridge is carried out at the same time the cartridge is held inposition for the purpose of pulling a film end from the cartridge.Consequently, this process and a process of inspecting a pull resistanceto the film from the cartridge are conducted substantiallysimultaneously. The inspecting processes can thus be carried outefficiently.

[0172] Although certain preferred embodiments of the present inventionhave been shown and described in detail, it should be understood thatvarious changes and modifications may be made therein without departingfrom the scope of the appended claims.

What is claimed is:
 1. A method of processing a film in a film producingand packaging system for unreeling an elongate photosensitivephotographic film from a film roll, cutting the photosensitivephotographic film to predetermined film lengths, winding each of thefilm length on a spool, and placing the film length wound on the spoolinto a cartridge, comprising the steps of: detecting whether facilitiesof the film producing and packaging system have suffered a failure; ifeither one of the facilities has suffered a failure, manually restoringsaid one of the facilities and manually discharging the photosensitivephotographic film by a length from said one of the facilities; andautomatically discharging a length of the photosensitive photographicfilm which corresponds to a predetermined number of film lengths to becut from the photosensitive photographic film, from said one of thefacilities which has been restored.
 2. A method according to claim 1,further comprising the steps of: detecting a trailing end of thephotosensitive photographic film fully unreeled from said film roll;splicing the detected trailing end of the photosensitive photographicfilm to a leading end of a new photosensitive photographic film unreeledfrom a new film roll; discharging the spliced photosensitivephotographic film from a discharge mechanism disposed closely to acutting mechanism; detecting a spliced region of the photosensitivephotographic films with a splicing detecting mechanism disposed upstreamof said cutting mechanism while the spliced photosensitive photographicfilm is being discharged; and discharging the length of thephotosensitive photographic films corresponding to the predeterminednumber of film lengths based on a detected signal representing thespliced region of the photosensitive photographic films.
 3. A methodaccording to claim 1, further comprising the steps of: detecting atrailing end of the photosensitive photographic film fully unreeled fromsaid film roll; splicing the detected trailing end of the photosensitivephotographic film to a leading end of a new photosensitive photographicfilm unreeled from a new film roll; and discharging the splicedphotosensitive photographic film by the length corresponding to thepredetermined number of film lengths based on a detected signalrepresenting the trailing end of the photosensitive photographic film,from a discharge mechanism disposed closely to a cutting mechanism.
 4. Amethod according to claim 3, further comprising the step of: shuttingoff said one of the facilities as suffering the failure if a splicedregion of the photosensitive photographic films is not detected by asplicing detecting mechanism within a predetermined discharge lengthwhen the photosensitive photographic film is discharged from saiddischarge mechanism.
 5. A method according to claim 1, furthercomprising the step of: storing a defect on said film roll in advance;converting information as to the stored defect into information as tothe number of cut film lengths as counted from, a leading end of thephotosensitive photographic film unreeled from said film roll; countingfilm lengths cut from the photosensitive photographic film as thephotosensitive photographic film is unreeled from said film roll; and ifthe counted cut film lengths agrees with the converted number of cutfilm lengths, automatically discharging the photosensitive photographicfilm by a length corresponding to the converted number of cut filmlengths.
 6. A method of processing a film, comprising the steps of:unreeling an elongate photosensitive photographic film from a film roll;feeding the photosensitive photographic film by a predetermined cutlength and stopping the photosensitive photographic film in a cuttingposition; applying first and second inspecting beams to a passage alongwhich a plurality of spaced holes defined in a side edge of thephotosensitive photographic film move, while said photosensitivephotographic film is being stopped in said cutting position; andindividually detecting whether said first and second inspecting beamspass through respective ones of said holes or not, and deciding whetherneither one of the holes is positioned in said cutting position or not,based on detected results.
 7. A method according to claim 6, furthercomprising the step of: determining that neither one of the holes ispositioned in said cutting position only if said first and secondinspecting beams pass through respective ones of said holes.
 8. A methodaccording to claim 6, further comprising the step of: determining thatneither one of the holes is positioned in said cutting position only ifsaid first inspecting beam is blocked by said photosensitivephotographic film and said second inspecting beam passes through one ofsaid holes.
 9. A method according to claim 6, further comprising thestep of: automatically discharging a defective film cut from saidphotosensitive photographic film if either one of the holes is judged asbeing positioned in said cutting position.
 10. A method according toclaim 6, further comprising the step of: forming perforations as saidholes at spaced intervals in the side edge of said photosensitivephotographic film as unreeled from said film roll.
 11. A method ofprocessing a film, comprising the steps of: detecting whether a cap ismounted on a cartridge or not in synchronism with holding said cartridgeafter a photosensitive photographic film wound around a spool is placedin said cartridge; and detecting a pulling load on a film end which isbeing pulled from said cartridge thereby to inspect a processed state ofsaid film end.
 12. A method according to claim 11, further comprisingthe step of: judging a resistance to pulling said film end as acceptableonly if said pulling load is smaller than a first pulling loadimmediately after the film end starts being pulled out and if saidpulling load is smaller than a second pulling load which is smaller thansaid first pulling load after the film end is pulled out by apredetermined length.
 13. A method according to claim 11, furthercomprising the step of: automatically discharging said cartridge withoutbeing delivered to an encasing process if the processed state of saidfilm end is judged as being unacceptable.
 14. A method of processing afilm, comprising the steps of: detecting whether a cap is reliablystaked on a cartridge or not in synchronism with holding said cartridgeafter a photosensitive photographic film wound around a spool is placedin said cartridge; and detecting a pulling load on a film end which isbeing pulled from said cartridge thereby to inspect a resistance topulling said film end.
 15. A method according to claim 14, furthercomprising the step of: judging the resistance to pulling said film endas acceptable only if said pulling load is smaller than a first pullingload immediately after the film end starts being pulled out and if saidpulling load is smaller than a second pulling load which is smaller thansaid first pulling load after the film end is pulled out by apredetermined length.
 16. A method according to claim 14, furthercomprising the step of: automatically discharging said cartridge withoutbeing delivered to an encasing process if the resistance to pulling saidfilm end is judged as being unacceptable.
 17. A method of processing afilm, comprising the steps of: detecting whether a cap is mounted on acartridge or not in synchronism with holding said cartridge after aphotosensitive photographic film wound around a spool is placed in saidcartridge; detecting whether the cap is reliably staked on the cartridgeor not; and detecting a pulling load on a film end which is being pulledfrom said cartridge thereby to inspect a resistance to pulling said filmend.
 18. A method according to claim 17, further comprising the step of:judging the resistance to pulling said film end as acceptable only ifsaid pulling load is smaller than a first pulling load immediately afterthe film end starts being pulled out and if said pulling load is smallerthan a second pulling load which is smaller than said first pulling loadafter the film end is pulled out by a predetermined length.
 19. A methodaccording to claim 17, further comprising the step of: automaticallydischarging said cartridge without being delivered to an encasingprocess if the resistance to pulling said film end is judged as beingunacceptable.
 20. An apparatus for processing in a film producing andpackaging system for unreeling an elongate photosensitive photographicfilm from a film roll, cutting the photosensitive photographic film topredetermined film lengths, winding each of the film length on a spool,and placing the film length wound on the spool into a cartridge,comprising: a trailing end position detect mechanism for detecting atrailing end of the photosensitive photographic film fully unreeled fromsaid film roll; a splicing mechanism for splicing the detected trailingend of the photosensitive photographic film to a leading end of a newphotosensitive photographic film unreeled from a new film roll; adischarge mechanism positionable closely to a cutting mechanism, fordischarging the spliced photosensitive photographic film; a splicingdetecting mechanism disposed upstream of said cutting mechanism, fordetecting a spliced region of the photosensitive photographic films; anda control mechanism for discharging a length of the photosensitivephotographic films corresponding to a predetermined number of filmlengths to be cut from the photosensitive photographic films, based on adetected signal from said splicing detecting mechanism.
 21. An apparatusfor processing in a film producing and packaging system for unreeling anelongate photosensitive photographic film from a film roll, cutting thephotosensitive photographic film to predetermined film lengths, windingeach of the film length on a spool, and placing the film length wound onthe spool into a cartridge, comprising: a trailing end position detectmechanism for detecting a trailing end of the photosensitivephotographic film fully unreeled from said film roll; a splicingmechanism for splicing the detected trailing end of the photosensitivephotographic film to a leading end of a new photosensitive photographicfilm unreeled from a new film roll; a discharge mechanism positionableclosely to a cutting mechanism, for discharging the splicedphotosensitive photographic film; and a control mechanism fordischarging a length of the spliced photosensitive photographic filmscorresponding to a predetermined number of film lengths to be cut fromthe photosensitive photographic films, based on a detected signal fromsaid trailing end position detect mechanism.
 22. An apparatus accordingto claim 21, further comprising: memory means for storing a defect onsaid film roll in advance; cut film length number information convertingmeans for converting positional information as to the stored defect intoinformation as to the number of cut film lengths as counted from aleading end of the photosensitive photographic film unreeled from saidfilm roll; counting means for counting film lengths cut from thephotosensitive photographic film as the photosensitive photographic filmis unreeled from said film roll; and a control circuit for, if thecounted cut film lengths agrees with the converted number of cut filmlengths, automatically discharging the photosensitive photographic filmby a length corresponding to the converted number of cut film lengths.23. An apparatus according to claim 21, further comprising a splicingdetecting mechanism for detecting a spliced region of the photosensitivephotographic films to determine a defect thereon while thephotosensitive photographic films are being discharged by said dischargemechanism.
 24. An apparatus for processing a film, comprising: first andsecond inspecting means disposed toward a passage along which aplurality of spaced holes defined in a side edge of the photosensitivephotographic film move, for applying respective first and secondinspecting beams to said passage; and decision means for, while saidphotosensitive photographic film is being stopped in a cutting position,individually detecting whether said first and second inspecting beamspass through respective ones of said holes or not, and deciding whetherneither one of the holes is positioned in said cutting position or not,based on detected results.
 25. An apparatus according to claim 24,wherein said decision means comprising means for determining thatneither one of the holes is positioned in said cutting position only ifsaid first and second inspecting beams pass through respective ones ofsaid holes.
 26. An apparatus according to claim 24, wherein saiddecision means comprising means for determining that neither one of theholes is positioned in said cutting position only if said firstinspecting beam is blocked by said photosensitive photographic film andsaid second inspecting beam passes through one of said holes.
 27. Anapparatus according to claim 24, wherein said first and secondinspecting means comprise first and second infrared photosensors,respectively.
 28. An apparatus according to claim 24, further comprisingperforating means for forming perforations as said holes at spacedintervals in the side edge of said photosensitive photographic film asunreeled from said film roll.
 29. An apparatus for processing a film,comprising: a cartridge holding mechanism for holding a cartridgestoring a photosensitive photographic film wound around a spool; a capdetecting mechanism mounted on said cartridge holding mechanism, fordetecting whether a cap is mounted on said cartridge or not; and apulling load detecting mechanism for detecting a pulling load on a filmend which is being pulled from said cartridge while said cartridge isbeing held by said cartridge holding mechanism thereby to inspect aresistance to pulling said film end.
 30. An apparatus according to claim29, wherein said cartridge holding mechanism comprises a holder forpressing and holding said cartridge, and said cap detecting mechanismcomprises a proximity sensor embedded in said holder.
 31. An apparatusaccording to claim 29, wherein said pulling load detecting mechanismcomprises: gripping means for gripping said film end, said grippingmeans being movable in a direction to pull said film end from saidcartridge; and a load cell for detecting the pulling load imposed onsaid film end when said film end is pulled from said cartridge by saidgripping means.
 32. An apparatus for processing a film, comprising: acartridge holding mechanism for holding a cartridge storing aphotosensitive photographic film wound around a spool; a heightdetecting mechanism for inspecting a cap on said cartridge for acrimping while said cartridge is being held by said cartridge holdingmechanism; and a pulling load detecting mechanism for detecting apulling load on a film end which is being pulled from said cartridgewhile said cartridge is being held by said cartridge holding mechanismthereby to inspect a resistance to pulling said film end.
 33. Anapparatus according to claim 32, wherein said pulling load detectingmechanism comprises: gripping means for gripping said film end, saidgripping means being movable in a direction to pull said film end fromsaid cartridge; and a load cell for detecting the pulling load imposedon said film end when said film end is pulled from said cartridge bysaid gripping means.
 34. An apparatus according to claim 32, whereinsaid cartridge holding mechanism has a vertically movable rod, saidheight detecting mechanism comprising: a detecting member fixed to saidvertically movable rod; and a distance sensor disposed in apredetermined vertical position with respect to said detecting member,for detecting a distance from said detecting member.
 35. An apparatusfor processing a film, comprising: a cartridge holding mechanism forholding a cartridge storing a photosensitive photographic film woundaround a spool; a cap detecting mechanism mounted on said cartridgeholding mechanism, for detecting whether a cap is mounted on saidcartridge or not; a height detecting mechanism for inspecting said capfor a crimping while said cartridge is being held by said cartridgeholding mechanism; and a pulling load detecting mechanism for detectinga pulling load on a film end which is being pulled from said cartridgewhile said cartridge is being held by said cartridge holding mechanismthereby to inspect a resistance to pulling said film end.
 36. Anapparatus according to claim 35, wherein said pulling load detectingmechanism comprises: gripping means for gripping said film end, saidgripping means being movable in a direction to pull said film end fromsaid cartridge; and a load cell for detecting the pulling load imposedon said film end when said film end is pulled from said cartridge bysaid gripping means.
 37. An apparatus according to claim 35, whereinsaid cartridge holding mechanism has a vertically movable rod, saidheight detecting mechanism comprising: a detecting member fixed to saidvertically movable rod; and a distance sensor disposed in apredetermined vertical position with respect to said detecting member,for detecting a distance from said detecting member.